Printed warp knit and process of making the same

ABSTRACT

The invention relates to a mattress fabric constructed of a warp polyester/spandex or nylon/spandex knit that may be imprinted with at least one aesthetically pleasing design, and a process for manufacturing the printed warp knit fabric.

CROSS REFERENCE TO PRIOR APPLICATIONS

This application claims priority and the benefit thereof from a U.S. Provisional Application No. 61/393,112, filed on Oct. 14, 2010 and entitled NEW MATTRESS TICKING, the entire contents of which are herein incorporated by reference.

FIELD OF THE INVENTION

The invention relates to a mattress fabric constructed of a warp polyester/spandex or nylon/spandex knit that may be imprinted with at least one aesthetically pleasing design, and a process for manufacturing the printed warp knit fabric.

BACKGROUND OF THE INVENTION

Fabrics currently used to encase a mattress include circular knits, woven and warp knits without spandex. These mattress fabrics have a limited comfort level for the consumer using the mattress. In addition, mattress covers, commonly known as mattress ticking, are typically manufactured in solid colors such as white, cream, and tan, and are typically not very aesthetically stimulating or inviting to the consumer. A need exists to manufacture a mattress ticking that allows for better stretch and recovery properties thereby improving the consumer's overall comfort when using the mattress, and promote mattress sales by offering mattresses with attractive prints, colors, and other visually stimulating covers.

A person sleeping on a mattress may lie in a prone or semi-prone position for much of the night, for an estimated six to ten hours. Pressure accumulates on the points where the person's body lies is in contact with the mattress. Persons who sleep on their sides face greater pressure on their shoulder and hip regions that may result in less optimal spinal alignment and possibly greater discomfort during sleep. In addition to greater pressure points, the areas surrounding the body's contact with the mattress may face increased temperature and warmth, and greater body perspiration, which may be unable to dissipate from the body.

Mattress manufacturers have attempted to address the problems of differential pressure by creating multi-zone support elements and use of new types of foams, latexes, gels and other mattress components to improve mattress comfort. These elements have ranged from altered patterns on the mattress surface, varying depths and concentrations of convolutions in foam layers, variations in types of foam, variations in steel spring coil geometry, spacing and independence, to use of varying modular elements that can be specified to provide more or less support according to a person's height, weight, and body type.

Current mattress ticking fabrics, the strong and tightly woven fabrics or the circular knits used to make mattress coverings, are limited by its stretch and recovery properties which dampen the feel of the mattress components underneath the mattress ticking. This limitation to the mattress ticking serves to enhance pressure points on the consumer's body when the consumer is using the mattress. This also creates an insulation layer because of the nature of the construction that reduces breathability and so on.

There is a need for fabrics that allow consumers to better feel the foam, latexes, gels, and other mattress components unencumbered by stiffness in the mattress ticking, allow for better stretch and recovery of the fabric to reduce pressure points along the body, promote the mattress's fashionable style and market appeal and the like.

SUMMARY OF THE INVENTION

The invention, as described below discloses a mattress fabric, specifically, the mattress ticking, including fabrics having at least one of polyester/spandex combination content or nylon/spandex combination content which optimizes a user's comfort when sleeping on the mattress due to the greater stretch and recovery properties of the fabrics and the like. This invention also discloses at least one design incorporated onto the mattress ticking including at least one printed image which provides visual stimulation to the consumer and promotes the mattress' aesthetic appeal.

The invention may be implemented in a number of ways. According to one aspect, the invention is directed to a mattress that includes a fabric configured to be arranged on the external surface of the mattress having at least one of polyester and spandex combination content, nylon and spandex combination, spandex; and the fabric further having one of a warp knit and circular knit construction.

Accordingly, in another aspect of the invention, a mattress includes a fabric configured to be arranged on the external surface of the mattress and at least one image design incorporated onto the fabric substrate through printing technology.

According to another aspect of the invention, a process for manufacturing fabric configured for an external surface of the mattress includes knitting the fabric having at least one of polyester/spandex combination content; nylon/spandex combination content, and spandex, and arranging the fabric on the external surface of the mattress, wherein the fabric comprises one of a warp knit and circular knit construction

Additional features, advantages, and embodiments of the invention may be set forth or apparent from consideration of the detailed description and drawings. Moreover, it is to be understood that both the foregoing summary of the invention and the following detailed description are exemplary and intended to provide further explanation without limiting the scope of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a further understanding of the invention, are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the detailed description serve to explain the principal of the invention. No attempt is made to show structural details of the invention and the various ways in which it may be practiced. In the drawings:

FIG. 1 shows an example of a mattress ticking having a warp knit polyester spandex and/or nylon spandex combination content, with a print image of a city landscape on the sleeping side of the mattress;

FIG. 2 shows an example of a mattress ticking having a warp knit polyester spandex and/or nylon spandex combination content, with a print image of an electric guitar on the sleeping side of the mattress; and

FIG. 3 shows an example of a flow diagram for a process of manufacturing a printed warp knit, according to an aspect of the invention.

The present invention is further described in the detailed description that follows.

DETAILED DESCRIPTION OF THE INVENTION

The embodiments of the invention and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments and examples that are described and/or illustrated in the accompanying drawings and detailed in the following attached description. It should be noted that the features illustrated in the drawings are not necessarily drawn to scale, and features of one embodiment may be employed with other embodiments as the skilled artisan would recognize, even if not explicitly stated herein. Descriptions of well-known components and processing techniques may be omitted so as to not unnecessarily obscure the embodiments of the invention. The examples used herein are intended merely to facilitate an understanding of ways in which the invention may be practiced and to further enable those of skill in the art to practice the embodiments of the invention. Accordingly, the examples and embodiments herein should not be construed as limiting the scope of the invention. Moreover, it is noted that like reference numerals represent similar parts throughout the several views of the drawings.

The invention set forth describes a mattress ticking having increased comfort as a result of the type of materials and/or type of manufacturing. The invention may use at least one of a polyester and spandex combination content fabric, nylon and spandex combination fabric, or blends of both. Additionally, the invention may use blends with other fibers. Furthermore, the invention may use blends of fibers with spandex that offer special and improved comfort. The fabric of the invention may have further increased comfort through the manufacturing process. The process may include an approach where the fabric is made on a warp knit machine, either Tricot or Rachel. Additionally, the fabric may be constructed using a jersey stitch. Further, the jersey stitch may be a reverse jersey stitch. The top bar of the warp knit machine may have a stitch configuration of 2-3, 1-0. The bottom bar of the warp knit machine may have a stitch configuration of 1-0, 1-2. Although these are specific configurations, the fabric may have other stitch formations that give a similar result.

A fabric constructed as noted above is similar to fabric constructions used in making active apparel, has better stretch and recovery than other mattress ticking fabrics currently on the market, and will reduce the person's pressure points and improve overall comfort when using the mattress such as by wicking moisture away from the body. Treatments such as antimicrobial, phase-change material and the like may be added to further enhance the comfort. Other treatments may be added to enhance or improve the useful life of the mattress ticking fabric.

Mattress ticking available today is typically offered in solid, neutral colors such as white, cream, or light brown. The mattress ticking can play a vitally important role with consumers and retailers from a sales and marketing perspective because consumers may be attracted to the design, color, and visual stimulation that the mattress ticking can generate. The invention is additionally or alternatively directed to updating the look and style of the mattress by incorporating a print image onto the fabric substrate and offers mattress manufacturers and retailers a new and limitless design medium to attract the consumer in the purchase of a fashionable mattress. The print may be on one sleeping side of the mattress, both sleeping sides of the mattress and/or the mattress depth bordering the sleeping sides of the mattress.

The image, such as for example a digital image, may be applied to the mattress ticking using ink jet, stamping, stencil, lithographic, offset, heat transfer, electrophotography, gravure, rotary printing, screen printing (rotary, flat-bed, etc.) or like technology, or any combination thereof. The image itself may undergo some type of pre-treatment to enhance the visual aspects of the print or reduce image fading over time, prior to being applied to the mattress ticking. The mattress ticking may undergo some type of pre-treatment before the image is applied to the fabric possibly to increase the useful life of the fabric or introduce other benefits. Alternatively, or in addition to pre-treatment, the mattress ticking and/or image may undergo some type of post-treatment after the image is applied to the fabric possibly to increase the useful life of the fabric or introduce other benefits. The mattress ticking may also be manufactured without any type of treatment.

A customer may select from a number of image choices maintained by the manufacturer, wholesaler, or retailer as a library of images, or the customer may customize the image by providing at least one customer generated image to the manufacturer. Nevertheless, the ticking of the invention does not require image printing and can be simply used plain or dyed to create a desired color.

FIG. 1 shows an example of a mattress ticking having a warp knit polyester spandex and/or nylon spandex combination content, with a print image of a city landscape on the sleeping side of the mattress.

Referring to FIG. 1, the mattress ticking selected by the customer is an image of a city landscape that may have originated from a library catalog of the manufacturer or provided by the consumer. The city landscape 110 was digitally imprinted on the sleeping surface of the mattress 100 but no image was selected for the mattress depth 120. The warp knit is made on a warp knit machine with fabric consisting of polyester spandex and/or nylon and spandex combination as discussed in detail above. Alternatively, the customer may select multiple prints and create a collage of images to be imprinted on the mattress ticking. The mattress 100 in this FIG. 1 is twin size, but may be California king, king, queen, full, toddler bed or any other commercially available size and configuration.

FIG. 2 shows an example of a mattress ticking having a warp knit polyester spandex and/or nylon spandex combination content, with a print image of an electric guitar on the sleeping side of the mattress.

Referring to FIG. 2, the mattress ticking selected by the customer is an image of an electric guitar that may have originated from a library catalog of the manufacturer or provided by the consumer. The guitar 210 was digitally imprinted on the sleeping surface of the mattress 200 but no image was selected for the mattress depth 220. The warp knit is made on a warp knit machine with fabric consisting of polyester spandex and/or nylon and spandex combination as discussed in detail above. Alternatively, the customer may select multiple prints and create a collage of images to be imprinted on the mattress ticking. The mattress 200 in this FIG. 2 is twin size, but may be California king, king, queen, full, toddler bed or any other commercially available size and configuration.

This invention also involves a process for manufacturing a mattress ticking including at least one of polyester/spandex combination content or nylon/polyester combination content described above in combination with an image design as described above. The invention also contemplates use of the image on any mattress ticking.

FIG. 3 shows an example of a flow diagram for a process of manufacturing a printed warp knit, according to an aspect of the invention.

Referring to FIG. 3, the process may begin when a mattress ticking is manufactured 310. The mattress ticking may have one of a polyester and spandex combination content, nylon and spandex combination, or such blends with other fibers and spandex as described above. The mattress ticking may be manufactured on a warp knit machine 310, preferably Tricot or Rachel, in a common industry stitch configuration as mentioned above.

The knit fabric may be pre-treated 320 using industry standard pre-treatment technologies with antimicrobial, phase-change materials, or other enhancements to improve the fabrics useful life or consumer's comfort. This pre-treatment may also take place prior to manufacture of the ticking 310.

Consumers wanting to personalize their mattress may select a print image from the manufacturer's or retailer's library of images, or may submit their own print image or images 330 to be applied to the mattress ticking. At consumer's option, the selected print image(s) may be pre-treated 340 using industry standard pre-treatment technologies to better enhance the quality and improve the images of the print before the prints are applied to the mattress ticking. The print images may then be applied to the knit fabric 350. Consumers may select an image or a collage of images to apply to the knit fabric to be placed on the sleeping surface of the mattress ticking. In addition, consumers may also select an image or a collage of images to apply to the kit fabric that will cover the mattress depth. Also, the manufacturer may simply select an image to be applied to the fabric.

At the consumer's option, and for additional fees, the knit fabric may be post-treated 360 using industry standard treatment technologies with antimicrobial, phase-change materials, or the like. Other enhancements to improve the fabrics useful life or consumer's comfort are also contemplated.

Finally, the knit fabric may be conformed to the mattress 370 of the consumer's choice. Alternatively, the consumer may have selected an “off-the-shelf” pre-maid mattress with mattress ticking design available at the retail establishment rather than customize its own mattress ticking and mattress. In addition, the consumers may also select a mattress with mattress ticking of a polyester/spandex combination, nylon/spandex combination, or other such blends with fibers and spandex manufactured without a digital print.

The above-noted process and arrangement is also contemplated for use with mattress pads, sheets, pillows, pillow covers, mattress covers, blankets, comforters, duvets, and the like.

While the invention has been described in terms of exemplary embodiments, those skilled in the art will recognize that the invention can be practiced with modifications in the spirit and scope of the appended claims. These examples given above are merely illustrative and are not meant to be an exhaustive list of all possible designs, embodiments, applications or modifications of the invention. 

1. A mattress comprising: a fabric configured to be arranged on the external surface of the mattress comprising at least one of: polyester and spandex combination content; nylon and spandex combination; spandex; and said fabric further comprising one of a warp knit and circular knit construction.
 2. The mattress ticking of claim 1, wherein the fabric comprises one of a Tricot and Rachel.
 3. The mattress ticking of claim 2, wherein the fabric comprises a jersey stitch.
 4. The mattress ticking of claim 3, wherein the jersey stitch comprises a reverse jersey stitch.
 5. The mattress ticking of claim 3, wherein the jersey stitch comprises a top stitch configuration of 2-3, 1-0.
 6. The mattress ticking of claim 3, wherein the jersey stitch comprises a bottom stitch configuration of 1-0, 1-2.
 7. The mattress ticking of claim 3, wherein the jersey stitch comprises a top stitch configuration of 2-3, 1-0 and a bottom stitch configuration of 1-0, 1-2.
 8. The mattress ticking of claim 3, wherein the ticking fabric spans the width and length of the mattress surface of at least one side of a sleeping surface.
 9. The mattress ticking of claim 3, wherein at least one image design is incorporated onto the fabric substrate through printing technology.
 10. The mattress ticking of claim 3, wherein said ticking is a removable cover.
 11. The mattress ticking cover of claim 3, wherein said cover is a replacement cover for the original mattress ticking cover.
 12. A mattress comprising: a fabric configured to be arranged on the external surface of the mattress and at least one image design incorporated onto the fabric substrate through printing technology.
 13. The mattress ticking of claim 12, wherein the image design covers at least one of: one sleeping side; two sleeping sides; and mattress depth connecting the two sleeping sides.
 14. The mattress ticking of claim 13, wherein the fabric is configured to be arranged on the external surface of the mattress comprising at least one of: polyester and spandex combination content; nylon and spandex combination; spandex; and said fabric further comprising one of a warp knit and circular knit construction.
 15. The mattress ticking of claim 13, wherein said ticking is a removable cover.
 16. The mattress ticking cover of claim 13, wherein said cover is a replacement cover for the original mattress ticking cover.
 17. A process for manufacturing fabric configured for an external surface of the mattress comprising: knitting the fabric having at least one of polyester/spandex combination content; nylon/spandex combination content, and spandex; and arranging the fabric on the external surface of the mattress, wherein the fabric comprises one of a warp knit and circular knit construction.
 18. The process of claim 17, further comprising knitting one of a Tricot and Rachel fabric.
 19. The process of claim 17, further comprising forming a reverse jersey stitch.
 20. The process of claim 17, further comprising forming a reverse jersey stitch with at least one of a top stitch configuration of 2-3, 1-0, a bottom stitch configuration of 1-0, 1-2, and both configurations.
 21. The process of claim 17, further comprising applying an image using imaging technology. 